Gear Manufacturing & Inspection: Methods, Practices, Application & Interpretation for the Design Engineer DATE: June 20-22, 2017 8:00 am – 5:00 pm LOCATION: St. Augustine, FL INSTRUCTOR Information Raymond J. Drago Email: [email protected] COURSE INFORMATION Course Description Learn key factors in the inspection process that lead to better design of gears. Develop a broad understanding of the methods used to manufacture and inspect gears. Discover how the resultant information can be applied and interpreted in the design process. This course also includes a tour of Riley Gear, St. Augustine, FL. Pre-requisites: None It is recommended that you spend a minimum of 1 hour reading and reviewing the material each day. Learning Objectives: • Identify methods of manufacturing external and internal spur, single and double helical, and bevel and worm gears • Describe the methodology and underlying theory for basic manufacture and inspection of each. • Discuss the “features” associated with each manufacturing method with regard to their impact upon and their ability to refine, guide and optimize the design process. • Take two views of the same results: meeting a “specification” and determining acceptability for a specific application, and interpreting the inspection data for purposes other than simply determining accept/reject status. • Specify the data required to control both the manufacturing and inspection processes on an engineering drawing. This includes both the data to be defined and the presentation of the data on the engineering drawing. • Discuss the basics of a variety of destructive and nondestructive inspection tests, including their underlying theory, application techniques and, most importantly, interpretation of the resultant data. Required Textbooks – provided by AGMA AGMA’s Gear Manufacturing & Inspection: Methods, Practices, Application & Interpretation for the Design Engineer, by Raymond J. Drago. 1 COURSE OUTLINE I. SUMMARY OF GEAR x. Roll Forming MANUFACTURING PROCESS • Parallel Axis Gears a. Generating • Worm Gears b. Forming y. Roll Finishing A. Gear c. Non-controlled Manufacturing z. Generating Straight Bevel Gears II. GENERATING PROCESSES With Disk Tools a. Hobbing • Cutting Rack Tooth Form • Grinding Gang Hobbing Special Hops for Internal Gears III. FORMING PROCESSES Hobbing Spiral Bevel Gears a. Form Milling b. Shaping b. Slotting Stroke c. Gashing d. Form Grinding Continuous • Aluminum Oxide Wafer Cutters • CBN c. Gear Planning e. Broaching Rack Cutters f. Shearing CBN Hard Cutting g. Forging Backer Bars • Net Shape d. Face Milling • Near Net Shape e. Skiving • Powder Processes f. Generating Grinding • Die Casting g. Roll Forming • Injection Molding • Extrusion h. Disk Milling • Stamping i. Hobbing • Flame Cutting j. Shaping – Pinion Shaped Tool • Electrical Discharge Machining k. Disk Cutter • Photo Chemical Machining l. Shaping m. Continuous Rack Shaping INSPECTION n. Special Purpose Machines I. PURPOSES • Face Milling Spiral Bevel Gears a. Accept/Reject p. Face Hobbing Spiral Bevel Gears b. Determine Acceptability for q. Skiving With Carbide Hob Application r. Hard Finishing Bevel Gears s. Generating Grinding Parallel Axis II. TYPES OF INSPECTION Gears • Conical Wheel III. GEOMETRIC • Saucer Shaped Wheel a. Chart Identification & Part • Threaded Wheel Orientation t. Generating Grinding Bevel Gears b. Use and Interpretation of AGMA u. Bevel Gear Planning quality numbers v. Bevel Gear Planning Generator w. Two Tool Generator – Straight Bevel IV. ELEMENTAL Gears a. Involute Profile b. Lead c. Tooth Spacing 2 d. Runout e. Tooth Thickness f. Surface Finish STUDENT FEEDBACK AND GRADING PROCEDURES Assignments Assignments and learning activities are given and directed at the discretion of the instructor. COURSE MANAGEMENT Weather Delays and Cancelations We will communicate any cancellations, delays or other concerns for safety prior to class via email, voicemail, and/or text message. Please be sure that we have all pertinent contact information as you travel to your class location. Attendance for Domestic and International Students Please be mindful that these are short, accelerated courses. Attendance is extremely important. If you are going to be absent from any class day, please contact the course coordinator. Casandra Blassingame, Director, [email protected] or Kellyanne Broom, Coordinator, [email protected]. Plagiarism, Cheating and other types of Misconduct Plagiarism1, cheating and other types of misconduct are unacceptable. Students with Disabilities Students requiring assistance and accommodation should complete the Special Accommodation Request form and submit it to Kellyanne Broom at [email protected]. She can be reached at 703-838-0069. Grievance Procedures Students who have concerns about the class are encouraged to contact Casandra Blassingame, Director of Education at [email protected] or 703-838-0055. Outline Changes The instructor reserves the right to modify the outline during the course of the class. LEARNING AND OTHER RESOURCES Links for writing resources: • grammar.ccc.commnet.edu/grammar • www.merriam-webster.com Links for Math resources: 1 Plagiarism is defined as “the use or close imitation of the language and thoughts of another author and the representation of them as one’s own original work.” 3 • www.sosmath.com • Khan Academy on www.youtube.com Links for time management, study skills and note taking resources: • www.mindtools.com • www.testakingtips.com Links for career resources: • https://www.agma.org/newsroom/jobs/ Industry News: • https://www.agma.org/newsroom/industry-news/ 4 .